POLISH MARITIME RESEARCH 2 (102) 2019 Vol. 26; pp.

126-133
10.2478/pomr-2019-0032

APPLICATION OF REVERSE ENGINEERING TECHNOLOGY IN PART

DESIGN FOR SHIPBUILDING INDUSTRY

Mariusz Deja1
Michał Dobrzyński1
Marcin Rymkiewicz2
1
Gdansk University of Technology, Faculty of Mechanical Engineering,
Department of Manufacturing and Production Engineering, Poland
2
„Scan 3D”, Gdynia, Poland

ABSTRACT

In the shipbuilding industry, it is difficult to create CAD models of existing or prototype parts, especially with many
freeform surfaces. The paper presents the creation of the CAD 3D model of a shipbuilding component with the application
of the reverse engineering technology. Based on the data obtained from the digitization process, the component is
reconstructed in point cloud processing programs and the CAD model is created. Finally, the accuracy of the digital
model is estimated.

Keywords: reverse engineering, laser scanning, freeform surface, measurement techniques

INTRODUCTION measuring instruments, mechanical devices, scanning lasers,

and photogrammeters [10].
Minimising the time needed for preparing a new project, Reverse engineering, in combination with laser scanning
with the resulting reduction of production costs, is of technologies and post-processing, is extremely useful in
special importance in both implementing new innovative redesigning, testing, and updating the structure of watercraft
watercraft structures and retrofitting the existing ones. components. Measuring and modelling of such a component
Reverse engineering (RE) is one of the methods used to with the aid of conventional measurement methods is very
support these activities, in particular for controlling the difficult, as it refers, as a rule, to a product with geometrically
quality of elements used in shipbuilding, redesigning complex freeform shapes. In this case, the use of scanned data
prototype structures, retrofitting existing constructions, in the form of clouds of points allows the seagoing watercraft
etc. The main measurement methods used for shape data designer to create a precise CAD 3D model, which can then be
acquisition in the marine industry are: conventional manual used for assessing the quality of manufacturing, as well as for

126 POLISH MARITIME RESEARCH, No 2/2019

CAE system-based redesigning, engineering and simulation engineering-based approach to support regeneration of
tests, etc. This way, the laser scanning technology supports the worn out parts. The CAD/CAM system generates tool paths
ship control process and provides a method of data acquisition for a device which will execute the virtual repair process,
which may turn out profitable for the shipbuilding industry for instance for a robot welding a joint to fill the damaged
due to its time and cost saving nature. According to the ASE area of the regenerated part with a given volume of welding
report on the National Shipbuilding Research Programme material. Then, this part is machined on a five-axis CNC
(NSRP), 3D laser scanning during ship data acquisition and milling machine to a required dimension.
postprocessing can decrease the cost by 37% and time by 39%, The use of modern measurement techniques in combination
compared to traditional methods making use of traditional/ with additive techniques makes it possible to produce a wide
manual measuring instruments [13]. variety of parts needed, for instance, to repair damaged
The reverse engineering technology is also used for devices on ships or offshore steel structures [6, 18], or in the
supporting engineering calculations [23, 25], and to obtain automotive industry [15]. A structurally advanced group of
more accurate results in highly precise machining [26]. Its products with complex geometry and higher-quality surface
use also makes it possible to increase the accuracy of geodetic requirements are high-pressure stage blades in gas turbines
and astronomical measurements performed using radio used in ship propulsion systems or in Tesla turbines. The
telescopes [24] and to investigate and assess the architectonic geometry of these blades is very complex, with additional
heritage [22]. elements such as holes and passages intended to deliver the
The following chapters of the article present: the literature cooling medium under the blade surface. The blades are tested
review on the use of reverse engineering, especially in the both experimentally on real prototype objects, and with the
shipbuilding industry, and the methodology of CAD 3D aid of numerical methods [8].
model creation with the use of the reverse engineering Manufacturing of hull elements is one of key processes
technology for a given ship component. Then, based on the in shipbuilding. However, this process is still performed
data obtained from the digitisation process, the component at low degree of automation. From 30% to 70% of typical
is reconstructed in computer programmes for point cloud ship hulls comprise parts with freeform surfaces shaped by
processing and the CAD model is created. The final stage of experienced workers. The hull part measurement system is
the analysis is the accuracy assessment of the digitised model. a component of the production automation system which
allows the production assistance programme to generate
proper data for part shaping [9]. In [14], large hull parts were
LITERATURE REVIEW scanned, after which the measured data were compared with
the required geometry to check whether the required shape
The use of modern CAD/CAM systems and special was achieved and to select heating line parameters for possible
measuring instruments for creating CAD 3D models of shape correction in further operations. The experiments were
existing objects plays a key role in reverse engineering [19, performed on real ship hull parts, and the obtained results
20], especially in the case of large-size elements [1] in the demonstrated a possibility for automating the production
shipbuilding industry [14, 16] and aeronautics [7]. This is process on the shipyard’s heating line.
of special importance for a model of the part created in the The complex object modelling methodology which
absence of digital data related with the reconstructed object utilizes photogrammetric and laser methods to generate
or when the part is to be retrofitted. The problem which a high-density cloud of points was presented by Menna
consisted in applying reverse engineering techniques to and Troisi [12]. The structures analysed by them were small
retrofit the existing watercraft, or in the absence of basic screw propellers, and the obtained results demonstrated the
technical data, such as construction plans, the data on the applicability of a hybrid approach which integrates the two
hull and machines installed on the deck, and/or working considered technologies. The use of digital photogrammetric
drawings of components, was studied by Tasseti at al. [17]. techniques for modelling 3D objects is essential in designing
As far as object reconstruction is concerned, its requirements marine screw propellers and complex hull geometries [3].
depend on the planned application, i.e. whether it is part In [16], using a 12-metre long yacht as an example,
replication, reconstruction, measurement, and/or modification a methodology was presented for determining the symmetry
related with change of the structure of the analysed model. plane of an object based on the cloud of points obtained from
Part modification can be easily performed following the laser scanning or other measurement techniques. Precise
approach presented in [19], which assumes reconstructing finding of the vertical symmetry plane of the examined yacht
the design concept from the already existing objects. The provided opportunities for correct assessment of its future
obtained 3D models are based on geometric features (feature- behaviour during the navigation. A possibility to increase
based) and comprise the geometry description which provides the accuracy of measurements of prototype ship models
opportunities for easy introduction of constructional changes built in decreased scale was presented in [2], where fast and
to new innovative applications. A similar approach proposed compact terrestrial laser scanners (TLS) were used for this
in [4, 5] is additionally combined with virtual machining, purpose. In that case the measurement accuracy was of special
which makes it possible to recognise technological features importance, as all measurement errors would be multiplied
(feature recognition). In [11], the authors propose the reverse on the full-scale object.

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 OBJECT OF EXAMINATION of finishing, among other features. Basic parameters of the
AND MEASUREMENT METHODS laser head are given in Table 1.
Tab. 1. Parameters of MMDx 100 laser head
The object of examination was the housing of the main Accuracy (1σ) 10 μm
propulsion propeller shaft for a newly designed vessel.
Stripe width (Y) 100 mm
The initial product was a prototype element made using
Measuring range (Z) 100 mm
a conventional lamination technology with additional
machining of selected structural elements. It had overall Stand-off 100 mm
dimensions φ290 × 425 mm and numerous freeform surfaces Min. point resolution 65 μm
which ensured correct functioning of the entire unit during Max. data rate 150 Hz
yacht navigation in marine conditions (Fig. 1). Laser power Class 2, 660 nm

The data generated by the 3D laser scanner were analysed

using the Geomagic software, mainly Design X and Wrap
[21]. After analysing and processing, the obtained clouds
of points and triangle meshes made a basis for generating
a parametric CAD model of the real prototype object. Then,
using the processed scan of the element as a basis, a CAD
3D model was created in the Autodesk Inventor software.
The final verification of this model was performed using the
Geomagic Control X software.

RESULTS OF TESTS

The process of object surface digitisation was performed

with the laser beam of 100 mm in width, as shown in Fig. 2a.
The raw data obtained in the above way have the form of
a cloud of points shown in Fig. 2b. Then, the point-defined
object was converted to a so-called polygon model by imposing
a surface of triangles onto the cloud of points (Fig. 3a).
Noteworthy are the defects which appear during model
surface mapping (Fig. 3b). They result from two main causes:
collection of insufficient number of data points in some object
surface areas, and surface and/or geometry imperfections of
the real prototype object resulting from insufficient precision
of its manufacturing.
a)

Fig. 1. View of prototype product

The measurements were performed using a 7-axis

articulated measuring arm SMART Arm 7 2.5 produced by
Nikon Smart Solutions, with the measuring range of 2,5 m,
volumetric accuracy of ± 0,043 mm, and point repeatability
of 0,030 mm (uncertainty within the entire operating range
of the arm, values given for 2 sigma). The arm was made of
light and durable materials: carbon fibre, aluminium, and
titanium.
The measuring arm was equipped with a MMDx Nikon
Metrology laser scanner, with laser beam width of 100 mm.
The maximum number of really scanned points per second
was 80 000. The Model Maker laser head was equipped with
the Enhanced Scanning Performance (ESP3) technology,
which adapted the laser power to the type of surface of
the scanned object, for instance its structure and quality

128 POLISH MARITIME RESEARCH, No 2/2019

b) applied to increase the accuracy of adaptation of the filling
to the surrounding mesh by dividing each discontinuous
element into smaller parts. All this made it possible to
reconstruct more precisely the areas in which the data from
scanning were incomplete or missing.

Fig. 2. Product surface digitisation with the aid of measuring arm SMART
Arm 7 equipped with laser head MMDx 100 (a) and cloud of points obtained
from the measurement (b)
Fig. 4. Object imperfections identified after digitisation as surface
discontinuities in the CAD model

Fig. 3. Polygon model of the object (a), examples of surface defects (b) The final refinement of the model was performed using
the pre-installed functions “Relaxpolygons” which made it
possible to smooth the model locally and improve the mesh.
In was therefore necessary to reconstruct the model mesh This was done by setting three main parameters: smoothing
by filling small holes, smoothing and cleaning the mesh, level, force, and required curvature, in selected areas of the
removing model discontinuities and double walls, etc. This model. The final view of the digitised model of the examined
task was performed using mathematical algorithms directly part is shown in Fig. 5a, and the corresponding *.stl view
implemented in Geomagic software. Moreover, some free- prepared in Inventor software in Fig. 5b.
standing triangles which represented noise in the mesh (red
areas) were removed (Fig. 3b).
Larger defects which came into existence as a result of the
digitisation process and had the form of holes and surface
discontinuities were removed using various programming
functions, (Fig. 4). For instance, the function “bridge” was

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 Fig. 5. View of object model after correcting measures (a), and *.stl model The accuracy of the created CAD 3D model of the examined
prepared in Autodesk Inventor software (b) part was assessed using Geomagic Control X, an advanced
software package used for controlling the quality of products
The obtained triangle mesh was used in the redesign based on point clouds recorded by scanning devices. In the
process, which was performed under the assumptions of examined case, the scanned 3D object was compared with
preserving the initial prototype geometry, especially the the created CAD 3D model and the resulting deviations were
freeform surfaces, and meeting the symmetry condition analysed.
by the product to be designed. Hybrid modelling functions The CAD 3D model control was done after importing the
were used for this purpose, such as the functions of rotation following files:
about axis, extrusion, and linking of solids, for instance. • Reference data – the symmetrical CAD 3D model of the
The accuracy of the created model was assumed at the level product, created in Autodesk Inventor software based
of about +/- 1,5 mm. Fig. 6a shows the final CAD 3D model on the modified *.stl file prepared in Geomagic software.
(yellow) along with the applied *.stl mesh, while Fig. 6b • Control data – the *.stl file being the input data for editing
presents selected views of the model. the point cloud in Geomagic software.

Fig. 6. CAD 3D model of the object after redesigning and *.stl mesh (a),
selected views (b) Based on the measurement report, the maximum deviation
of the measured data from the CAD model was 7,66 mm
(Fig. 7a). The average deviation over the entire model was

130 POLISH MARITIME RESEARCH, No 2/2019

0,59 mm, with standard deviation SD= 1,75 mm. Large • Due to faults and discontinuities of the object, the process
maximum deviation values are not acceptable taking into of point cloud processing after digitisation is crucial for
consideration the function of the product. The observed errors the entire task and requires special software.
mainly result from the applied production technology which • The accuracy of a CAD 3D model obtained in the redesign
did not ensure preservation of the basic structural condition, process can be assessed by comparing with data from
i.e. geometrical symmetry of the product. This deficiency is measurements. In the analysed case, the average deviation
clearly visible in the view of the propeller shaft guide sleeve over the entire model was 0,59 mm, with standard deviation
(Fig. 7b). SD= 1,75 mm.

Fig. 7. Measuring report (a) and view of guide sleeve (b) • The maximal deviation reached nearly 7,66 mm, which
was associated with the lack of symmetry of the prototype
product caused by the applied production technology.
Therefore, it is advisable to apply an alternative production
CONCLUSIONS process to ensure that the product will meet constructional
requirements.
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CONTACT WITH THE AUTHORS

Mariusz Deja
e-mail: [email protected]

Gdańsk University of Technology

Faculty of Mechanical Engineering
Department of Manufacturing
and Production Engineering
G. Narutowicza 11/12, 80-233 Gdańsk
Poland

Michał Dobrzyński
e-mail: [email protected]

Gdańsk University of Technology

Faculty of Mechanical Engineering
Department of Manufacturing
and Production Engineering
G. Narutowicza 11/12, 80-233 Gdańsk
Poland

Marcin Rymkiewicz
e-mail: [email protected]

Scan 3D
J. Sobieskiego 13, 81-198 Gdynia
Poland

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